Absorbent articles with channels

ABSTRACT

The present disclosure is directed, in part, to an absorbent article that comprises an absorbent core disposed at least partially intermediate a topsheet and a backsheet and a core wrap enclosing an absorbent material. The core wrap comprises a first material and a second material. The first material forms a C-wrap at least partially around the second material. The absorbent material comprises at least 80% of superabsorbent polymers by weight of the absorbent material. The absorbent core comprises a channel substantially free of the superabsorbent polymers, at least partially oriented in a longitudinal direction of the article, and comprising an arcuate portion. The channel has lateral widths taken parallel to a lateral axis of the article. The profile of the lateral widths of the channel over a longitudinal length of at least 50 mm of the channel taken along the longitudinal axis is substantially constant.

FIELD

The present disclosure is generally directed to absorbent articles forpersonal hygiene such as baby diapers, training pants, adultincontinence products, and/or sanitary napkins. The absorbent articlesmay each comprise channels and/or pockets.

BACKGROUND

Absorbent articles for personal hygiene, such as disposable diapers forinfants, training pants for toddlers, adult incontinence undergarments,and/or sanitary napkins are designed to absorb and contain bodyexudates, in particular large quantities of urine or menses. Theseabsorbent articles comprise several layers providing differentfunctions, for example, a topsheet, a backsheet, and an absorbent coredisposed between the topsheet and the backsheet, among other layers.

The function of the absorbent core is to absorb and retain the exudatesfor a prolonged amount of time, for example, overnight for a diaper,minimize re-wet to keep the wearer dry, and avoid soiling of clothes orbed sheets. The majority of currently marketed absorbent articlescomprise as absorbent material which is a blend of comminuted wood pulpwith superabsorbent polymers (SAP) in particulate form, also calledabsorbent gelling materials (AGM). Absorbent articles having a coreconsisting essentially of SAP as absorbent material (so called“airfelt-free” cores) have also been proposed but are less common thantraditional mixed cores.

Some absorbent articles may typically comprise leg cuffs which provideimproved containment of liquids and other body exudates. Leg cuffs mayalso be referred to as leg bands, side flaps, barrier cuffs, or elasticcuffs. Usually, each leg cuff comprises one or more elastic strings orelements comprised in the chassis of the diaper, for example, betweenthe topsheet and backsheet in the area of the leg openings to provide aneffective seal while the absorbent article is in use. These elasticizedelements which are substantially planar with the chassis of theabsorbent article will be referred to herein as gasketing cuffs. It isalso usual for the leg cuffs to comprise raised elasticized flaps,herein referred to as barrier leg cuffs, which improve the containmentof fluid in the leg-torso joint regions.

Absorbent articles generally have a high absorbent capacity and theabsorbent core may expand several times its weight and volume. Theseincreases may cause the absorbent articles to sag in the crotch regionas they become saturated with liquid, which may cause the barrier legcuffs to partially lose contact with the wearer's skin. This may lead toa loss of functionality of the barrier leg cuffs, with the increasedpossibly of leakage.

Although various solutions to this problem have been proposed, the fieldcan benefit from additional channel and/or pocket configurations thatimproved leakage prevention in absorbent articles.

SUMMARY

In an embodiment, the present disclosure is directed, in part, to anabsorbent article that may comprise a front waist edge or front edge, arear waist edge or rear edge longitudinally opposing the front waistedge, a first side edge, a second side edge laterally opposing the firstside edge, a longitudinal axis extending from a midpoint of the frontwaist edge to a midpoint of the rear waist edge, and a lateral axisextending from a midpoint of the first side edge to a midpoint of thesecond side edge. The absorbent article may also comprise a liquidpermeable topsheet, a liquid impermeable backsheet, and a pair ofbarrier leg cuffs extending at least partially between the front waistedge and the rear waist edge on opposite sides of the longitudinal axis.Each barrier leg cuff may comprise a proximal edge joined to thetopsheet or the backsheet and a free terminal edge. The absorbentarticle may also comprise an absorbent core disposed at least partiallyintermediate the topsheet and the backsheet and may comprise a core wrapenclosing an absorbent material. The core wrap may comprise a firstmaterial and a second material. The first material may form a C-wrap atleast partially around the second material. The absorbent material maycomprise at least 80% of superabsorbent polymers by weight of theabsorbent material. The absorbent core may comprise a channelsubstantially free of the superabsorbent polymers, at least partiallyoriented in the longitudinal direction of the article, and comprising anarcuate portion. The channel has lateral widths taken parallel to thelateral axis. The profile of the lateral widths of the channel over alongitudinal length of at least 50 mm of the channel taken along thelongitudinal axis may be substantially constant. Other embodiments arealso within the scope of the present disclosure, including embodimentsfor sanitary napkins.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features and advantages of the presentdisclosure, and the manner of attaining them, will become more apparentand the disclosure itself will be better understood by reference to thefollowing description of non-limiting embodiments of the disclosuretaken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a top view of an absorbent article with some layers partiallyremoved in accordance with a non-limiting embodiment of the presentdisclosure;

FIG. 2 is a cross-sectional view of the absorbent article taken aboutline 2-2 of FIG. 1 in accordance with a non-limiting embodiment of thepresent disclosure;

FIG. 3 is a view of the absorbent article of FIG. 2 where the absorbentarticle has been loaded with fluid in accordance with a non-limitingembodiment of the present disclosure;

FIG. 4 is a top view of another absorbent article with some layerspartially removed in accordance with a non-limiting embodiment of thepresent disclosure;

FIG. 5 is a cross-sectional view of the absorbent article taken aboutline 5-5 of FIG. 4 in accordance with a non-limiting embodiment of thepresent disclosure;

FIG. 6 is a top view of an absorbent core of the absorbent article ofFIG. 4 with some layers partially removed in accordance with anon-limiting embodiment of the present disclosure;

FIG. 7 is a cross-sectional view of the absorbent core taken about line7-7 of FIG. 6 in accordance with a non-limiting embodiment of thepresent disclosure;

FIG. 8 is a cross-sectional view of the absorbent core taken about line8-8 of FIG. 6 in accordance with a non-limiting embodiment of thepresent disclosure;

FIG. 9 is a top view of an absorbent core for an absorbent article inaccordance with a non-limiting embodiment of the present disclosure;

FIG. 10 is a profile of the sum of the lateral widths of two channels ofFIG. 9 graphed against the longitudinal length of the channels withinthe enclosed area “EA” in accordance with a non-limiting embodiment ofthe present disclosure;

FIG. 11 is a profile of the sum of the lateral widths of portions of thechannels of FIG. 1 graphed against the longitudinal length of thechannels between lines A and B of FIG. 1 in accordance with anon-limiting embodiment of the present disclosure;

FIG. 12 is a top view of an absorbent core for an absorbent article inaccordance with a non-limiting embodiment of the present disclosure;

FIG. 13 is a profile of the sum of the lateral widths of portions of thechannels and the pocket of FIG. 12 graphed against the longitudinallength of the channels between lines C and D of FIG. 12 in accordancewith a non-limiting embodiment of the present disclosure;

FIGS. 14-21 are top views of absorbent cores for absorbent articles inaccordance with various non-limiting embodiments of the presentdisclosure; and

FIG. 22 is a top view of an absorbent article that is a sanitary napkinwith some of the layers cut away in accordance with a non-limitingembodiment of the present disclosure.

DETAILED DESCRIPTION

Various non-limiting embodiments of the present disclosure will now bedescribed to provide an overall understanding of the principles of thestructure, function, manufacture, and use of the absorbent articles withchannel configurations and methods for making the same disclosed herein.One or more examples of these non-limiting embodiments are illustratedin the accompanying drawings. Those of ordinary skill in the art willunderstand that the absorbent articles with channel configurations andmethods for making the same described herein and illustrated in theaccompanying drawings are non-limiting example embodiments and that thescope of the various non-limiting embodiments of the present disclosureare defined solely by the claims. The features illustrated or describedin connection with one non-limiting embodiment may be combined with thefeatures of other non-limiting embodiments. Such modifications andvariations are intended to be included within the scope of the presentdisclosure.

Introduction

As used herein, the term “absorbent article” refers to disposabledevices such as infant, child, or adult diapers, training pants,sanitary napkins, and the like which are placed against or in proximityto the body of the wearer to absorb and contain the various exudatesdischarged from the body. Typically, these articles comprise a topsheet,backsheet, an absorbent core, optionally an acquisition system (whichmay be comprised of one or several layers), and typically othercomponents, with the absorbent core normally placed at least partiallybetween the backsheet and the acquisition system or between the topsheetand the backsheet. The absorbent articles of the present disclosure willbe further illustrated in the below description and in the Figures inthe form of a taped diaper. Nothing in this description should be,however, considered limiting the scope of the claims. As such thepresent disclosure applies to any suitable form of absorbent articles(e.g., training pants, adult incontinence products, sanitary napkins).

A “nonwoven web” as used herein means a manufactured sheet, web, or battof directionally or randomly orientated fibers, bonded by friction,and/or cohesion, and/or adhesion, excluding paper and products which arewoven, knitted, tufted, stitch-bonded incorporating binding yarns orfilaments, or felted by wet-milling, whether or not additionallyneedled. The fibers may be of natural or man-made origin and may bestaple or continuous filaments or be formed in situ. Commerciallyavailable fibers may have diameters ranging from less than about 0.001mm to more than about 0.2 mm and may come in several different formssuch as short fibers (known as staple, or chopped), continuous singlefibers (filaments or monofilaments), untwisted bundles of continuousfilaments (tow), and twisted bundles of continuous filaments (yam).Nonwoven webs can be formed by many processes such as meltblowing,spunbonding, solvent spinning, electrospinning, carding, and airlaying.The basis weight of nonwoven webs is usually expressed in grams persquare meter (g/m² or gsm).

The term “joined” or “bonded” or “attached”, as used herein, encompassesconfigurations whereby an element is directly secured to another elementby affixing the element directly to the other element, andconfigurations whereby an element is indirectly secured to anotherelement by affixing the element to intermediate member(s) which in turnare affixed to the other element.

General Description of the Absorbent Article

An example absorbent article according to the present disclosure in theform of an infant diaper 20 is represented in FIGS. 1-3. FIG. 1 is aplan view of the example diaper 20, in a flat-out state, with portionsof the structure being cut-away to more clearly show the construction ofthe diaper 20. This diaper 20 is shown for illustration purpose only asthe present disclosure may be used for making a wide variety of diapersor other absorbent articles.

The absorbent article may comprise a liquid permeable topsheet 24, aliquid impermeable backsheet 25, an absorbent core 28 positioned atleast partially intermediate the topsheet 24 and the backsheet 25, andbarrier leg cuffs 34. The absorbent article may also comprise anacquisition-distribution system (“ADS”) 50, which in the examplerepresented comprises a distribution layer 54 and an acquisition layer52, which will be further detailed below. The absorbent article may alsocomprise elasticized gasketing cuffs 32 joined to the chassis of theabsorbent article, typically via the topsheet and/or backsheet, andsubstantially planar with the chassis of the diaper.

The Figures also show typical taped diaper components such as afastening system comprising adhesive tabs 42 attached towards the rearedge of the article and cooperating with a landing zone 44 on the frontof the article. The absorbent article may also comprise other typicalelements, which are not represented, such as a rear elastic waistfeature, a front elastic waist feature, transverse barrier cuff(s),and/or a lotion application, for example.

The absorbent article 20 comprises a front waist edge 10, a rear waistedge 12 longitudinally opposing the front waist edge 10, a first sideedge 3, and a second side edge 4 laterally opposing the first side edge3. The front waist edge 10 is the edge of the article which is intendedto be placed towards the front of the user when worn, and the rear waistedge 12 is the opposite edge. The absorbent article may have alongitudinal axis 80 extending from the lateral midpoint of the frontwaist edge 10 to a lateral midpoint of the rear waist edge 12 of thearticle and dividing the article in two substantially symmetrical halvesrelative to the longitudinal axis 80, with article placed flat andviewed from above as in FIG. 1. The absorbent article may also have alateral axis 90 extending from the longitudinal midpoint of the firstside edge 3 to the longitudinal midpoint of the second side edge 4. Thelength L of the article may be measured along the longitudinal axis 80from the front waist edge 10 to the rear waist edge 12. The width of thearticle may be measured along the lateral axis 90 from the first sideedge 3 to the second side edge 4. The article may comprise a crotchpoint C defined herein as the point placed on the longitudinal axis at adistance of two fifth (⅖) of L starting from the front edge 10 of thearticle 20. The article may comprise a front waist region 5, a rearwaist region 6, and a crotch region 7. The front waist region, the rearwaist region, and the crotch region each define ⅓ of the longitudinallength of the absorbent article.

The topsheet 24, the backsheet 25, the absorbent core 28, and the otherarticle components may be assembled in a variety of configurations, inparticular by gluing or heat embossing, for example. Example diaperconfigurations are described generally in U.S. Pat. No. 3,860,003, U.S.Pat. No. 5,221,274, U.S. Pat. No. 5,554,145, U.S. Pat. No. 5,569,234,U.S. Pat. No. 5,580,411, and U.S. Pat. No. 6,004,306. The absorbentarticle may be thin. The caliper at the crotch point C or in the crotchregion 7 of the article may be, for example, from 4.0 mm to 12.0 mm oralternatively from 6.0 mm to 10.0 mm.

The absorbent core 28 may comprise an absorbent material comprising atleast 80% by weight, at least 90% by weight, at least 95% by weight, orat least 99% by weight of superabsorbent polymers and a core wrapenclosing the superabsorbent polymers. The core wrap may typicallycomprise two materials, substrates, or nonwoven materials 16 and 16′ forthe top side and bottom side of the core. The core may comprises one ormore channels, represented in FIG. 1 as the four channels 26, 26′ and27, 27′.

These and other components of the articles will now be discussed in moredetails.

Topsheet

The topsheet 24 is the part of the absorbent article that is directly incontact with the wearer's skin. The topsheet 24 can be joined to thebacksheet 25, the core 28 and/or any other layers as is known to thoseof skill in the art. Usually, the topsheet 24 and the backsheet 25 arejoined directly to each other in some locations (e.g., on or close tothe periphery of the article) and are indirectly joined together inother locations by directly joining them to one or more other elementsof the article 20.

The topsheet 24 may be compliant, soft-feeling, and non-irritating tothe wearer's skin. Further, at least a portion of the topsheet 24 may beliquid permeable, permitting liquids to readily penetrate through itsthickness. A suitable topsheet may be manufactured from a wide range ofmaterials, such as porous foams, reticulated foams, apertured plasticfilms, or woven or nonwoven materials of natural fibers (e.g., wood orcotton fibers), synthetic fibers or filaments (e.g., polyester orpolypropylene or bicomponent PE/PP fibers or mixtures thereof), or acombination of natural and synthetic fibers. If the topsheet 24 includesfibers, the fibers may be spunbond, carded, wet-laid, meltblown,hydroentangled, or otherwise processed as is known in the art, inparticular spunbond PP nonwoven. A suitable topsheet comprising a web ofstaple-length polypropylene fibers is manufactured by Veratec, Inc., aDivision of International Paper Company, of Walpole, Mass. under thedesignation P-8.

Suitable formed film topsheets are also described in U.S. Pat. No.3,929,135, U.S. Pat. No. 4,324,246, U.S. Pat. No. 4,342,314, U.S. Pat.No. 4,463,045, and U.S. Pat. No. 5,006,394. Other suitable topsheets 30may be made in accordance with U.S. Pat. Nos. 4,609,518 and 4,629,643issued to Curro et al. Such formed films are available from The Procter& Gamble Company of Cincinnati, Ohio as “DRI-WEAVE” and from TredegarCorporation, based in Richmond, Va., as “CLIFF-T”.

Any portion of the topsheet 24 may be coated with a lotion as is knownin the art. Examples of suitable lotions include those described in U.S.Pat. No. 5,607,760, U.S. Pat. No. 5,609,587, U.S. Pat. No. 5,643,588,U.S. Pat. No. 5,968,025, and U.S. Pat. No. 6,716,441. The topsheet 24may also include or be treated with antibacterial agents, some examplesof which are disclosed in PCT Publication WO95/24173. Further, thetopsheet 24, the backsheet 25 or any portion of the topsheet orbacksheet may be embossed and/or matte finished to provide a more clothlike appearance.

The topsheet 24 may comprise one or more apertures to ease penetrationof exudates therethrough, such as urine and/or feces (solid, semi-solid,or liquid). The size of at least the primary aperture is important inachieving the desired waste encapsulation performance. If the primaryaperture is too small, the waste may not pass through the aperture,either due to poor alignment of the waste source and the aperturelocation or due to fecal masses having a diameter greater than theaperture. If the aperture is too large, the area of skin that may becontaminated by “rewet” from the article is increased. Typically, thetotal area of the apertures at the surface of a diaper may have an areaof between about 10 cm² and about 50 cm² or between about 15 cm² and 35cm². Examples of apertured topsheets are disclosed in U.S. Pat. No.6,632,504, assigned to BBA NONWOVENS SIMPSONVILLE. WO2011/163582 alsodiscloses suitable colored topsheet having a basis weight of from 12 to18 gsm and comprising a plurality of bonded points. Each of the bondedpoints has a surface area of from 2 mm² to 5 mm² and the cumulatedsurface area of the plurality of bonded points is from 10 to 25% of thetotal surface area of the topsheet.

Typical diaper topsheets have a basis weight of from about 10 to about21 gsm or from about 12 to about 18 gsm, but other basis weights arewithin the scope of the present disclosure.

Backsheet

The backsheet 25 is generally that portion of the article 20 positionedadjacent the garment-facing surface of the absorbent core 28 and whichprevents, or at least inhibits, the exudates absorbed and containedtherein from soiling articles such as bedsheets and undergarments. Thebacksheet 25 is typically impermeable, or at least substantiallyimpermeable, to liquids (e.g., urine). The backsheet may, for example,be or comprise a thin plastic film such as a thermoplastic film having athickness of about 0.012 mm to about 0.051 mm. Example backsheet filmsinclude those manufactured by Tredegar Corporation, based in Richmond,Va., and sold under the trade name CPC2 film. Other suitable backsheetmaterials may include breathable materials which permit vapors to escapefrom the diaper 20 while still preventing, or at least inhibiting,exudates from passing through the backsheet 25. Example breathablematerials may include materials such as woven webs, nonwoven webs,composite materials such as film-coated nonwoven webs, microporous filmssuch as manufactured by Mitsui Toatsu Co., of Japan under thedesignation ESPOIR NO and by Tredegar Corporation of Richmond, Va., andsold under the designation EXAIRE, and monolithic films such asmanufactured by Clopay Corporation, Cincinnati, Ohio under the nameHYTREL blend P18-3097.

The backsheet 25 may be joined to the topsheet 24, the absorbent core28, and/or any other element of the diaper 20 by any attachment methodsknown to those of skill in the art. Suitable attachment methods aredescribed above with respect to methods for joining the topsheet 24 toother elements of the article 20. For example, the attachment methodsmay include using a uniform continuous layer of adhesive, a patternedlayer of adhesive, or an array of separate lines, spirals, or spots ofadhesive. Suitable attachment methods comprising an open pattern networkof filaments of adhesive as disclosed in U.S. Pat. No. 4,573,986. Othersuitable attachment methods include using several lines of adhesivefilaments which are swirled into a spiral pattern, as is illustrated bythe apparatus and methods shown in U.S. Pat. No. 3,911,173, U.S. Pat.No. 4,785,996, and U.S. Pat. No. 4,842,666. Adhesives which have beenfound to be satisfactory are manufactured by H. B. Fuller Company of St.Paul, Minn. and marketed as HL-1620 and HL 1358-XZP. Alternatively, theattachment methods may comprise using heat bonds, pressure bonds,ultrasonic bonds, dynamic mechanical bonds, or any other suitableattachment methods or combinations of these attachment methods as areknown to those of skill in the art.

Absorbent Core

As used herein, the term “absorbent core” refers to the individualcomponent of the article having the most absorbent capacity andcomprising an absorbent material and a core wrap enclosing the absorbentmaterial. The term “absorbent core” does not include theacquisition-distribution system or layer or any other component of thearticle which is not either integral part of the core wrap or placedwithin the core wrap. The core may comprise, consist essentially of, orconsist of, a core wrap, absorbent material as defined below, and glueenclosed within the core wrap.

The absorbent core 28 of the present disclosure may comprise anabsorbent material with a high amount of superabsorbent polymers (hereinabbreviated as “SAP”) enclosed within a core wrap. The SAP content mayrepresent 70%-100% or at least 70%, 75%, 80%, 85%, 90%, 95%, 99%, or100% by weight of the absorbent material contained in the core wrap. Thecore wrap is not considered as absorbent material for the purpose ofassessing the percentage of SAP in the absorbent core.

By “absorbent material” it is meant a material which has some absorbencyproperty or liquid retaining properties, such as SAP, cellulosic fibersas well as synthetic fibers. Typically, glues used in making absorbentcores have no absorbency properties and are not considered as absorbentmaterial. The SAP content may be higher than 80%, for example at least85%, at least 90%, at least 95%, at least 99%, and even up to andincluding 100% of the weight of the absorbent material contained withinthe core wrap. This provides a relatively thin core compared toconventional core typically comprising between 40-60% SAP and highcontent of cellulose fibers. The absorbent material may in particularcomprises less than 15% or less than 10% weight percent of natural orsynthetic fibers, less than 5% weight percent, less than 3% weightpercent, less than 2% weight percent, less than 1% weight percent, ormay even be substantially free of natural and/or synthetic fibers. Theabsorbent material may advantageously comprise little or no airfelt(cellulose) fibers, in particular the absorbent core may comprise lessthan 15%, 10%, 5%, 3%, 2%, 1% airfelt (cellulose) fibers by weight ofthe absorbent core, or may even be substantially free of cellulosefibers.

The example absorbent core 28 of the absorbent article of FIGS. 4-5 isshown in isolation in FIGS. 6-8. The absorbent core may comprises afront side 280, a rear side 282, and two longitudinal sides 284, 286joining the front side 280 and the rear side 282. The absorbent core mayalso comprise a generally planar top side and a generally planar bottomside. The front side 280 of the core is the side of the core intended tobe placed towards the front waist edge 10 of the absorbent article. Thecore 28 may have a longitudinal axis 80′ corresponding substantially tothe longitudinal axis 80 of the article, as seen from the top in aplanar view as in FIG. 1. In an embodiment, the absorbent material maybe distributed in higher amount towards the front side than towards therear side as more absorbency may be required at the front in particulararticles. In an embodiment, the front and rear sides of the core may beshorter than the longitudinal sides of the core. The core wrap may beformed by two nonwoven materials, substrates, laminates, or othermaterials, 16, 16′ which may be at least partially sealed along thesides of the absorbent core. The core wrap may be at least partiallysealed along its front side 280, rear side 282, and two longitudinalsides 284, 286 so that substantially no absorbent material leaks out ofthe absorbent core wrap. The first material, substrate, or nonwoven 16may at least partially surround the second material, substrate, ornonwoven 16′ to form the core wrap, as illustrated in FIG. 7. The firstmaterial 16 may surround a portion of the second material 16′ proximateto the first and second side edges 284 and 286.

The absorbent core of the present disclosure may comprise adhesive, forexample, to help immobilizing the SAP within the core wrap and/or toensure integrity of the core wrap, in particular when the core wrap ismade of two or more substrates. The core wrap may extend to a largerarea than strictly needed for containing the absorbent material within.

Cores comprising relatively high amount of SAP with various core designsare disclosed in U.S. Pat. No. 5,599,335 (Goldman), EP 1,447,066(Busam), WO 95/11652 (Tanzer), U.S. Pat. Publ. No. 2008/0312622A1(Hundorf), and WO 2012/052172 (Van Malderen).

The absorbent material may be a continuous layer present within the corewrap. In other embodiments, the absorbent material may be comprised ofindividual pockets or stripes of absorbent material enclosed within thecore wrap. In the first case, the absorbent material may be, forexample, obtained by the application of a single continuous layer ofabsorbent material. The continuous layer of absorbent material, inparticular of SAP, may also be obtained by combining two absorbentlayers having discontinuous absorbent material application pattern,wherein the resulting layer is substantially continuously distributedacross the absorbent particulate polymer material area, as disclosed inU.S. Pat. Appl. Pub. No. 2008/0312622A1 (Hundorf), for example. Theabsorbent core 28 may comprise a first absorbent layer and a secondabsorbent layer. The first absorbent layer may comprise the firstmaterial 16 and a first layer 61 of absorbent material, which may be100% or less of SAP. The second absorbent layer may comprise the secondmaterial 16′ and a second layer 62 of absorbent material, which may alsobe 100% or less of SAP. The absorbent core 28 may also comprise afibrous thermoplastic adhesive material 51 at least partially bondingeach layer of absorbent material 61, 62 to its respective material 16 or16′. This is illustrated in FIGS. 7-8, as an example, where the firstand second SAP layers have been applied as transversal stripes or “landareas” having the same width as the desired absorbent materialdeposition area on their respective substrate before being combined. Thestripes may comprise different amount of absorbent material (SAP) toprovide a profiled basis weight along the longitudinal axis of the core80. The first material 16 and the second material 16′ may form the corewrap.

The fibrous thermoplastic adhesive material 51 may be at least partiallyin contact with the absorbent material 61, 62 in the land areas and atleast partially in contact with the materials 16 and 16′ in the junctionareas. This imparts an essentially three-dimensional structure to thefibrous layer of thermoplastic adhesive material 51, which in itself isessentially a two-dimensional structure of relatively small thickness,as compared to the dimension in length and width directions. Thereby,the fibrous thermoplastic adhesive material may provide cavities tocover the absorbent material in the land area, and thereby immobilizesthis absorbent material, which may be 100% or less of SAP.

The thermoplastic adhesive material 51 may comprise, in its entirety, asingle thermoplastic polymer or a blend of thermoplastic polymers,having a softening point, as determined by the ASTM Method D-36-95 “Ringand Ball”, in the range between 50° C. and 300° C., and/or thethermoplastic adhesive material may be a hotmelt adhesive comprising atleast one thermoplastic polymer in combination with other thermoplasticdiluents such as tackifying resins, plasticizers and additives such asantioxidants.

The thermoplastic adhesive used for the fibrous layer may haveelastomeric properties, such that the web formed by the fibers on theSAP layer is able to be stretched as the SAP swell. Example elastomeric,hotmelt adhesives include thermoplastic elastomers such as ethylenevinyl acetates, polyurethanes, polyolefin blends of a hard component(generally a crystalline polyolefin such as polypropylene orpolyethylene) and a Soft component (such as ethylene-propylene rubber);copolyesters such as poly (ethylene terephthalate-co-ethylene azelate);and thermoplastic elastomeric block copolymers having thermoplastic endblocks and rubbery mid blocks designated as A-B-A block copolymers:mixtures of structurally different homopolymers or copolymers, e.g., amixture of polyethylene or polystyrene with an A-B-A block copolymer;mixtures of a thermoplastic elastomer and a low molecular weight resinmodifier, e.g., a mixture of a styrene-isoprenestyrene block copolymerwith polystyrene; and the elastomeric, hot-melt, pressure-sensitiveadhesives described herein. Elastomeric, hot-melt adhesives of thesetypes are described in more detail in U.S. Pat. No. 4,731,066 issued toKorpman on Mar. 15, 1988.

The thermoplastic adhesive material may be applied as fibers. The fibersmay have an average thickness of about 1 to about 50 micrometers orabout 1 to about 35 micrometers and an average length of about 5 mm toabout 50 mm or about 5 mm to about 30 mm, specifically reciting all 0.1micrometer increments within the above-specified ranges and any rangesformed therein or thereby. To improve the adhesion of the thermoplasticadhesive material to the materials 16 or 16′ or to any other layer, inparticular any other nonwoven layers, such layers may be pre-treatedwith an auxiliary adhesive. The fibers adhere to each other to form afibrous layer, which can also be described as a mesh.

Superabsorbent Polymer (SAP)

“Superabsorbent polymers” (“SAP”), as used herein, refer to absorbentmaterials which are cross-linked polymeric materials that can absorb atleast 10 times their weight of an aqueous 0.9% saline solution asmeasured using the Centrifuge Retention Capacity (CRC) test (EDANAmethod WSP 241.2-05E). The SAP used may have a CRC value of more than 20g/g, more than 24 g/g, from 20 to 50 g/g, from 20 to 40 g/g, or from 24to 30 g/g, specifically reciting all 0.1 g/g increments within theabove-specified ranges and any ranges created therein or thereby. TheSAP useful with the present disclosure may include a variety ofwater-insoluble, but water-swellable polymers capable of absorbing largequantities of fluids.

The superabsorbent polymer may be in particulate form so as to beflowable in the dry state. Particulate absorbent polymer materials maybe made of poly(meth)acrylic acid polymers. However, starch-basedparticulate absorbent polymer material may also be used, as wellpolyacrylamide copolymer, ethylene maleic anhydride copolymer,cross-linked carboxymethylcellulose, polyvinyl alcohol copolymers,cross-linked polyethylene oxide, and starch grafted copolymer ofpolyacrylonitrile. The superabsorbent polymer may be polyacrylates andpolyacrylic acid polymers that are internally and/or surfacecross-linked. Suitable materials are described in the PCT PatentApplication Nos. WO 07/047,598, WO 07/046,052, WO2009/155265, andWO2009/155264, for example. In some embodiments, suitable superabsorbentpolymer particles may be obtained by generally known productionprocesses as described in WO 2006/083584, for example. Thesuperabsorbent polymers may be internally cross-linked, i.e., thepolymerization is carried out in the presence of compounds having two ormore polymerizable groups which can be free-radically copolymerized intothe polymer network. Useful crosslinkers include, for example, ethyleneglycol dimethacrylate, diethylene glycol diacrylate, allyl methacrylate,trimethylolpropane triacrylate, triallylamine, tetraallyloxyethane asdescribed in EP-A 530 438, di- and triacrylates as described in EP-A 547847, EP-A 559 476, EP-A 632 068, WO 93/21237, WO 03/104299, WO03/104300, WO 03/104301, and in DE-A 103 31 450, mixed acrylates which,as well as acrylate groups, include further ethylenically unsaturatedgroups, as described in DE-A 103 31 456 and DE-A 103 55 401, orcrosslinker mixtures as described, for example, in DE-A 195 43 368, DE-A196 46 484, WO 90/15830, and WO 02/32962 as well as cross-linkersdescribed in WO2009/155265. The superabsorbent polymer particles may beexternal surface cross-linked, or post cross-linked. Usefulpost-crosslinkers include compounds including two or more groups capableof forming covalent bonds with the carboxylate groups of the polymers.Useful compounds include for example alkoxysilyl compounds,polyaziridines, polyamines, polyamidoamines, di- or polyglycidylcompounds as described in EP-A 083 022, EP-A 543 303 and EP-A 937 736,polyhydric alcohols as described in DE-C 33 14 019, cyclic carbonates asdescribed in DE-A 40 20 780, 2-oxazolidone and its derivatives, such asN-(2-hydroxyethyl)-2-oxazolidone as described in DE-A 198 07 502, bis-and poly-2-oxazolidones as described in DE-A 198 07 992,2-oxotetrahydro-1,3-oxazine and its derivatives as described in DE-A 19854 573, N-acyl-2-oxazolidones as described in DE-A 198 54 574, cyclicureas as described in DE-A 102 04 937, bicyclic amide acetals asdescribed in DE-A 103 34 584, oxetane and cyclic ureas as described inEP1,199,327 and morpholine-2,3-dione and its derivatives as described inWO03/031482.

In some embodiments, the SAP may be formed from polyacrylic acidpolymers or polyacrylate polymers, for example, having a neutralizationdegree of from 60% to 90%, or of about 75%, having, for example, sodiumcounter ions.

The SAP useful for the present disclosure may be of numerous shapes. Theterm “particles” refers to granules, fibers, flakes, spheres, powders,platelets and other shapes and forms known to persons skilled in the artof superabsorbent polymer particles. In some embodiments, the SAPparticles can be in the shape of fibers, i.e., elongated, acicularsuperabsorbent polymer particles. In those embodiments, thesuperabsorbent polymer particles fibers may have a minor dimension(i.e., diameter of the fiber) of less than about 1 mm, usually less thanabout 500 μm, or less than 250 μm down to 50 μm, specifically recitingall 1 μm increments within the above-specified ranges and any rangesformed therein or thereby. The length of the fibers may be about 3 mm toabout 100 mm, specifically reciting all 1 mm increments within theabove-specified range and any ranges formed therein or thereby. Thefibers may also be in the form of a long filament that may be woven.

SAP may be spherical-like particles. In contrast to fibers,“spherical-like particles” have a longest and a smallest dimension witha particulate ratio of longest to smallest particle dimension in therange of 1-5, where a value of 1 would equate a perfectly sphericalparticle and 5 would allow for some deviation from such a sphericalparticle. The superabsorbent polymer particles may have a particle sizeof less than 850 μm, from 50 to 850 μm, from 100 to 710 μm, or from 150to 650 μm, specifically reciting all 1 μm increments within theabove-specified ranges and any ranges formed therein or thereby, asmeasured according to EDANA method WSP 220.2-05. SAP having a relativelylow particle size may help to increase the surface area of the absorbentmaterial which is in contact with liquid exudates and therefore supportsfast absorption of liquid exudates.

The SAP may have a particle sizes in the range from 45 μm to 4000 μm,more specifically a particle size distribution within the range of from45 μm to about 2000 μm, or from about 100 μm to about 1000, 850 or 600μm, specifically reciting all 1 μm increments within the above-specifiedranges and any ranges formed therein or thereby. The particle sizedistribution of a material in particulate form can be determined, forexample, by means of dry sieve analysis (EDANA 420.02 “Particle Sizedistribution).

In some embodiments herein, the superabsorbent material may be in theform of particles with a mass medium particle size up to 2 mm, between50 microns and 2 mm or to 1 mm, or from 100 μm, 200 μm, 300 μm, 400 μm,500 μm, 1000 μm, 800 μm, or 700 μm; as can, for example, be measured bythe method set out in for example EP-A-0,691,133. In some embodiments ofthe present disclosure, the superabsorbent polymer material is in theform of particles whereby at least 80% by weight are particles of a sizebetween 50 μm and 1200 μm and having a mass median particle size betweenany of the range combinations above. In addition, or in anotherembodiment of the present disclosure, the particles may be essentiallyspherical. In yet another or additional embodiment of the presentdisclosure, the superabsorbent polymer material may have a relativelynarrow range of particle sizes, e.g., with the majority (e.g., at least80%, at least 90%, at least 95%, or even at least 99% by weight) ofparticles having a particle size between 50 μm and 1000 μm, between 100μm and 800 μm, or between 200 μm and 600 μm, specifically reciting all 1μm increments within the above-specified ranges and any ranges formedtherein or thereby.

The surface of the SAP may be coated, for example, with a cationicpolymer. Certain cationic polymers may include polyamine or polyiminematerials. In some embodiments, the SAP may be coated with chitosanmaterials such as those disclosed in U.S. Pat. No. 7,537,832 B2. In someother embodiments, the SAP may comprise mixed-bed Ion-Exchange absorbentpolymers such as those disclosed in WO 99/34841 and WO 99/34842.

The absorbent core may comprise one or more types of SAP.

For most absorbent articles, liquid discharges from a wearer occurpredominately in the front half of the article, in particular for adiaper. The front half of the article (as defined by the region betweenthe front edge and a transversal line placed at a distance of half Lfrom the front waist edge 10 or rear waist edge 12 may thereforecomprise most of the absorbent capacity of the core. Thus, at least 60%of the SAP, or at least 65%, 70%, 75%, 80%, or 85% of the SAP may bepresent in the front half of the absorbent article, the remaining SAPbeing disposed in the rear half of the absorbent article. In otherembodiments, the SAP distribution may be uniform through the core or mayhave other suitable distributions.

The total amount of SAP present in the absorbent core may also varyaccording to expected user. Diapers for newborns may require less SAPthan infant, child, or adult incontinence diapers. The amount of SAP inthe core may be about 5 to 60 g or from 5 to 50 g, specifically recitingall 0.1 increments within the specified ranges and any ranged formedtherein or thereby. The average SAP basis weight within the (or “atleast one”, if several are present) deposition area 8 of the SAP may beat least 50, 100, 200, 300, 400, 500 or more g/m². The areas of thechannels (e.g., 27, 27′) present in the absorbent material depositionarea 8 are deduced from the absorbent material deposition area tocalculate this average basis weight.

Core Wrap

The core wrap may be made of a single substrate, material, or nonwovenfolded around the absorbent material, or may comprise two (or more)substrates, materials, or nonwovens which are attached to another.Typical attachments are the so-called C-wrap and/or sandwich wrap. In aC-wrap, as illustrated, for example, in FIGS. 2 and 7, the longitudinaland/or transversal edges of one of the substrates are folded over theother substrate to form flaps. These flaps are then bonded to theexternal surface of the other substrate, typically by gluing.

The core wrap may be formed by any materials suitable for receiving andcontaining the absorbent material. Typical substrate materials used inthe production of conventional cores may be used, in particular paper,tissues, films, wovens or nonwovens, or laminates or composites of anyof these. The core wrap may be formed by a nonwoven web, such as acarded nonwoven, spunbond nonwoven (“S”) or meltblown nonwoven (“M”),and laminates of any of these. For example, spunmelt polypropylenenonwovens may be suitable, in particular those having a laminate webSMS, or SMMS, or SSMMS, structure, and having a basis weight range ofabout 5 gsm to about 15 gsm. Suitable materials are disclosed in U.S.Pat. No. 7,744,576, U.S. Pat. Publ. No. 2011/0268932A1, U.S. Pat. Publ.No. 2011/0319848A1, and U.S. Pat. Publ. No. 2011/0250413A1. Nonwovenmaterials provided from synthetic fibers may also be used, such as PE,PET, and/or PP, for example.

If the core wrap comprises a first substrate, nonwoven or material 16and a second substrate, nonwoven, or materials 16′ these may be made ofthe same type of material, may be made of different materials, or one ofthe substrates may be treated differently than the other to provide itwith different properties. As the polymers used for nonwoven productionare inherently hydrophobic, they may be coated with hydrophilic coatingsif placed on the fluid receiving side of the absorbent core. It may beadvantageous that the top side of the core wrap, i.e., the side placedcloser to the wearer in the absorbent article, be more hydrophilic thanthe bottom side of the core wrap. A possible way to produce nonwovenswith durably hydrophilic coatings is via applying a hydrophilic monomerand a radical polymerization initiator onto the nonwoven, and conductinga polymerization activated via UV light resulting in monomer chemicallybound to the surface of the nonwoven. An alternative possible way toproduce nonwovens with durably hydrophilic coatings is to coat thenonwoven with hydrophilic nanoparticles, e.g., as described in WO02/064877.

Permanently hydrophilic nonwovens are also useful in some embodiments.Surface tension, as described in U.S. Pat. No. 7,744,576 (Busam et al.),can be used to measure how permanently a certain hydrophilicity level isachieved. Liquid strike through, as described in U.S. Pat. No.7,744,576, may be used to measure the hydrophilicity level. The firstand/or second substrate may have a surface tension of at least 55, atleast 60, or at least 65 mN/m or higher when wetted with salinesolution. The substrate may also have a liquid strike through time ofless than 5 seconds for a fifth gush of liquid. These values can bemeasured using the test methods described in U.S. Pat. No. 7,744,576B2:“Determination Of Surface Tension” and “Determination of Strike Through”respectively.

Hydrophilicity and wettability are typically defined in terms of contactangle and the strike through time of the fluids, for example, through anonwoven fabric. This is discussed in detail in the American ChemicalSociety publication entitled “Contact angle, wettability and adhesion”,edited by Robert F. Gould (Copyright 1964). A substrate having a lowercontact angle between the water and the surface of substrate may be saidto be more hydrophilic than another.

The substrates may also be air-permeable. Films useful herein maytherefore comprise micro-pores. The substrate may have anair-permeability of from 40 or from 50, to 300 or to 200 m³/(m²×min), asdetermined by EDANA method 140-1-99 (125 Pa, 38.3 cm²). The material ofthe core wrap may alternatively have a lower air-permeability, e.g.,being non-air-permeable, for example, to facilitate handling on a movingsurface comprising vacuum.

The core wrap may be at least partially sealed along all the sides ofthe absorbent core so that substantially no absorbent material leaks outof the core. By “substantially no absorbent material” it is meant thatless than 5%, less than 2%, less than 1%, or about 0% by weight ofabsorbent material escape the core wrap. The term “seal” is to beunderstood in a broad sense. The seal does not need to be continuousalong the whole periphery of the core wrap but may be discontinuousalong part or the whole of it, such as formed by a series of seal pointsspaced on a line. A seal may be formed by gluing and/or thermal bonding.

If the core wrap is formed by two substrates 16, 16′, four seals may beused to enclose the absorbent material 60 within the core wrap. Forexample, a first substrate 16 may be placed on one side of the core (thetop side as represented in the Figures) and extend around the core'slongitudinal edges to at least partially wrap the opposed bottom side ofthe core. The second substrate 16′ may be present between the wrappedflaps of the first substrate 16 and the absorbent material 60. The flapsof the first substrate 16 may be glued to the second substrate 16′ toprovide a strong seal. This so called C-wrap construction may providebenefits such as improved resistance to bursting in a wet loaded statecompared to a sandwich seal. The front side and rear side of the corewrap may then also be sealed by gluing the first substrate and secondsubstrate to another to provide complete encapsulation of the absorbentmaterial across the whole of the periphery of the core. For the frontside and rear side of the core, the first and second substrates mayextend and may be joined together in a substantially planar direction,forming for these edges a so-called sandwich construction. In theso-called sandwich construction, the first and second substrates mayalso extend outwardly on all sides of the core and be sealed flat, orsubstantially flat, along the whole or parts of the periphery of thecore typically by gluing and/or heat/pressure bonding. In an embodiment,neither the first nor the second substrates need to be shaped, so thatthey can be rectangularly cut for ease of production but other shapesare within the scope of the present disclosure.

The core wrap may also be formed by a single substrate which may encloseas in a parcel wrap the absorbent material and be sealed along the frontside and rear side of the core and one longitudinal seal.

SAP Deposition Area

The absorbent material deposition area 8 may be defined by the peripheryof the layer formed by the absorbent material 60 within the core wrap,as seen from the top side of the absorbent core. The absorbent materialdeposition area 8 may have various shapes, in particular, a so-called“dog bone” or “hour-glass” shape, which shows a tapering along its widthtowards the middle or “crotch” region of the core. In this way, theabsorbent material deposition area 8 may have a relatively narrow widthin an area of the core intended to be placed in the crotch region of theabsorbent article, as illustrated in FIG. 1. This may provide betterwearing comfort. The absorbent material deposition area 8 may thus havea width (as measured in the transversal direction) at its narrowestpoint which is less than about 100 mm, 90 mm, 80 mm, 70 mm, 60 mm, oreven less than about 50 mm. This narrowest width may further be at least5 mm, or at least 10 mm, smaller than the width of the deposition area 8at its largest point in the front and/or rear regions deposition area 8.The absorbent material deposition area 8 may also be generallyrectangular, for example as shown in FIGS. 4-6, but other depositionareas, such as a “T,” “Y,” “sand-hour,” or “dog-bone” shapes are alsowithin the scope of the present disclosure.

The basis weight (amount deposited per unit of surface) of the SAP mayalso be varied along the deposition area 8 to create a profileddistribution of absorbent material, in particular SAP, in thelongitudinal direction, in the transversal direction, or both directionsof the core. Hence, along the longitudinal axis of the core, the basisweight of absorbent material may vary, as well as along the transversalaxis, or any axis parallel to any of these axes. The basis weight of SAPin areas of relatively high basis weight may thus be at least 10%, 20%,30%, 40%, or 50% higher than in an area of relatively low basis weight.In one embodiment, the SAP present in the absorbent material depositionarea 8 at the level of the crotch point C may have more SAP per unit ofsurface deposited as compared to another area of the absorbent materialdeposition area 8.

The absorbent material may be deposited using known techniques, whichmay allow relatively precise deposition of SAP at relatively high speed.In particular, the SAP printing technology as disclosed in U.S. Pat.Publ. No. 2008/0312617 and U.S. Pat. Publ. No. 2010/0051166A1 (both toHundorf et al.) may be used. This technique uses a printing roll todeposit SAP onto a substrate disposed on a grid of a support which mayinclude a plurality of cross bars extending substantially parallel toand spaced from one another so as to form channels extending between theplurality of cross-bars. This technology allows high-speed and precisedeposition of SAP on a substrate. The channels of the absorbent core maybe formed for example by modifying the pattern of the grid and receivingdrums so that no SAP is applied in areas corresponding to the channels.EP application number 11169396.6 discloses this modification in moredetails.

Channels

The absorbent material deposition area 8 may comprise at least onechannel 26, which is at least partially oriented in the longitudinaldirection of the article 80 (i.e., has a longitudinal vector component).Other channels may be at least partially oriented in the lateraldirection (i.e., has a lateral vector component) or in any otherdirection. If the following, the plural form “channels” will be used tomean “at least one channel”. The channels may have a length L′ projectedon the longitudinal axis 80 of the article that is at least 10% of thelength L of the article. The channels may be formed in various ways. Forexample, the channels may be formed by zones within the absorbentmaterial deposition area 8 which may be substantially free of, or freeof, absorbent material, in particular SAP. In addition or alternatively,the channel(s) may also be formed by continuously or discontinuouslybonding the top side of the core wrap to the bottom side of the corewrap through the absorbent material deposition area 8. The channels maybe continuous but it is also envisioned that the channels may beintermittent. The acquisition-distribution system or layer 50, oranother layer of the article, may also comprise channels, which may ornot correspond to the channels of the absorbent core.

In some embodiments, the channels may be present at least at the samelongitudinal level as the crotch point C or the lateral axis 60 in theabsorbent article, as represented in FIG. 1 with the two longitudinallyextending channels 26, 26′. The channels may also extend from the crotchregion 7 or may be present in the front waist region 5 and/or in therear waist region 6 of the article.

The absorbent core 28 may also comprise more than two channels, forexample, at least 3, at least 4, at least 5, or at least 6 or more.Shorter channels may also be present, for example in the rear waistregion 6 or the front waist region 5 of the core as represented by thepair of channels 27, 27′ in FIG. 1 towards the front of the article. Thechannels may comprise one or more pairs of channels symmetricallyarranged, or otherwise arranged relative to the longitudinal axis 80.

The channels may be particularly useful in the absorbent core when theabsorbent material deposition area is rectangular, as the channels mayimprove the flexibility of the core to an extent that there is lessadvantage in using a non-rectangular (shaped) core. Of course channelsmay also be present in a layer of SAP having a shaped deposition area.

The channels may extend substantially longitudinally, which means thateach channel extends more in the longitudinal direction than in thetransverse direction, or at least twice as much in the longitudinaldirection than in the transverse direction (as measured after projectionon the respective axis). In other embodiments, the channels may extendsubstantially laterally, which means that each channel extends more inthe lateral direction than in the transverse direction, or at leasttwice as much in the longitudinal direction than in the transversedirection (as measured after projection on the respective axis).

The channels may be completely oriented longitudinally and parallel tothe longitudinal axis or completely oriented transversely and parallelto the lateral axis, but also may be curved. In various embodiments,some or all the channels, in particular the channels present in thecrotch region 7, may be concave towards the longitudinal axis 80, as,for example, represented in FIG. 1 for the pair of channels 26, 26′. Theradius of curvature may typically be at least equal (and may be at least1.5 or at least 2.0 times this average transverse dimension) to theaverage transverse dimension of the absorbent layer; and also straightbut under an angle of (e.g., from 5°) up to 30°, up to 20°, up to 10°with a line parallel to the longitudinal axis. The radius of curvaturemay be constant for a channel, or may vary along its length. This mayalso include channels with an angle therein, provided the angle betweentwo parts of a channel is at least 120°, at least 150°; and in any ofthese cases, provided the longitudinal extension of the channel is morethan the transverse extension. The channels may also be branched. Forexample, a central channel superposed with the longitudinal axis in thecrotch region 7 which branches towards the rear waist edge 12 and/ortowards the front waist edge 10 of the article.

In some embodiments, there is no channel that coincides with thelongitudinal axis 80 of the article or the core. When present assymmetrical pairs relative to the longitudinal axis 80, the channels maybe spaced apart from one another over their whole longitudinaldimension. The smallest spacing distance may be at least 5 mm, at least10 mm, or at least 16 mm, for example.

Furthermore, in order to reduce the risk of fluid leakages, thelongitudinal main channels may not extend up to any of the edges of theabsorbent material deposition area 8, and may therefore be fullyencompassed within the absorbent material deposition area 8 of the core.The smallest distance between a channel and the closest edge of theabsorbent material deposition area 8 may be at least 5 mm.

The channels may have a width Wc along at least part of its length whichis at least 2 mm, at least 3 mm, at least 4 mm, up to for example 20 mm,16 mm, or 12 mm, for example. The width of the channel may be constantthrough substantially the whole length of the channel or may vary alongits length. When the channels are formed by absorbent material-free zonewithin the absorbent material deposition area 8, the width of thechannels is considered to be the width of the material free zone,disregarding the possible presence of the core wrap within the channels.If the channels are not formed by absorbent material free zones, forexample mainly though bonding of the core wrap through the absorbentmaterial zone, the width of the channels if the width of this bonding.

At least some or all of the channels may be permanent channels, meaningtheir integrity is at least partially maintained both in the dry stateand in the wet state. Permanent channels may be obtained by provision ofone or more adhesive materials, for example, the fibrous layer ofadhesive material or construction glue that helps adhere a substratewith an absorbent material within the walls of the channel. Permanentchannels may also be formed by bonding the upper side and lower side ofthe core wrap (e.g., the first substrate 16 and the second substrate16′) and/or the topsheet 24 to the backsheet 25 together through thechannels. Typically, an adhesive may be used to bond both sides of thecore wrap or the topsheet and the a backsheet through the channels, butit is possible to bond via other known processes, such as pressurebonding, ultrasonic bonding, heat bonding, or combination thereof. Thecore wrap or the topsheet 24 and the backsheet 25 may be continuouslybonded or intermittently bonded along the channels. The channels mayadvantageously remain or become visible at least through the topsheetand/or backsheet when the absorbent article is fully loaded with afluid. This may be obtained by making the channels substantially free ofSAP, so they will not swell, and sufficiently large so that they willnot close when wet. Furthermore, bonding the core wrap to itself or thetopsheet to the backsheet through the channels may be advantageous.

FIG. 9 illustrates an example absorbent core 28 of the presentdisclosure. This core 28, and the cores illustrated in FIGS. 12 and14-20, may be used in the absorbent articles of the present disclosureand may have many or all of the features discussed herein. In variousembodiments, profiles of the sum of the lateral widths of one or morechannels (plotted on the Y-axis) may be plotted relative to thelongitudinal length about the longitudinal axis 80′ (plotted on theX-axis) of portions of the one or more channels. Stated another way, thesum of the lateral widths of the one or more channels over a particulara longitudinal length about the longitudinal axis 80′ of the one or morechannels may be plotted to create a profile.

To obtain data for such profiles, first, the absorbent article or theabsorbent core should be placed on a light table or a light sourcesuitable for viewing the channels within the absorbent core. If theabsorbent core is being used, it should first be removed from theabsorbent article using any suitable techniques. The wearer-facingsurface of the absorbent article or the absorbent core should face awayfrom the surface of the light table. The absorbent article or theabsorbent core should be attached to the light illuminating surface ofthe light table or light source using tape or other attachment members.Second, a longitudinal length along the longitudinal axis 80 or 80′(e.g., 5 mm, 10 mm, 15 mm, 20 mm, 50 mm, 100 mm) should be selected formeasurement. A rigid or flexible tape measure, graduated in mm, shouldbe used to measure the longitudinal length along the longitudinal axis80 or 80′. A dot should be placed on the absorbent article or theabsorbent core at either end of the longitudinal length on thelongitudinal axis 80 or 80′. Next, a line that is parallel to thelateral axis 90′ should be drawn through each dot. This enclosed area“EA” between the lines is the area to be measured. The enclosed area“EA” can be a portion of the absorbent article's or absorbent core'slongitudinal length or the entire length of the absorbent article orabsorbent core from the front waist edge 10 or front side 280 to therear waist edge 12 or rear side 282, respectively. In some instances, itmay be desirable to profile a large longitudinal length of the absorbentarticle or absorbent core, while, in other instances, it may bedesirable to profile a small longitudinal length. Once the longitudinallength to be used is indicated on the absorbent article or the absorbentcore, the sum of the lateral widths of the channels within the enclosedarea should be measured parallel to the lateral axis every 5 mm alongthe longitudinal length using the tape measure. If only one channel ispresent at a particular 5 mm increment within the enclosed area “EA”only one width will be the sum of the lateral widths of the channel atthat particular increment, while if more than one channel is present ata particular 5 mm increment within the enclosed area “EA”, the sum ofthe lateral widths at that increment will be the sum of those two ormore lateral widths of the channels. Those results should then beplotted to create a profile or graph with the sum of the lateral widthsof the one or more channels being plotted on the Y-axis and thelongitudinal length along the longitudinal axis 80 or 80′ at which theywere taken on the X-axis. The X-axis should be graduated in 5 mmincrements to correspond with lateral width measurements being takenevery 5 mm along the longitudinal axis 80 or 80′. The Y-axis may begraduated in 1 mm increments, 2 mm increments, or greater than 2 mmincrements depending on the values of the sum of the lateral widths ofthe one or more channels.

Referring to FIG. 9, as an example, the enclosed area “EA” is betweenthe two dashed lines at the end of the longitudinal length L′ of the oneor more channels along the longitudinal axis 80′. For all absorbent core28 embodiments, the longitudinal axis 80′ corresponds with thelongitudinal axis 80 of the absorbent article and the lateral axis 90′corresponds with the lateral axis 90 of the absorbent article. Lateralwidth measurements of the channels 26 and 26′ are taken parallel to thelateral axis 90′ every 5 mm. Each 5 mm increment is indicated as a line“L” in FIG. 9. The first measurement is taken 5 mm into the enclosedarea “EA” from the top dashed line “TL”. While FIG. 9 is not to scale, aprofile of the sum of the lateral widths taken in a direction parallelto the lateral axis 90′ every 5 mm along the longitudinal axis 80′ wouldlook generally like the example profile of FIG. 10. The longitudinallength along the longitudinal axis 80 is plotted on the X-axis and thesum of the lateral widths is plotted on the Y-axis. In this example, thesums of the laterals widths of the channels within the enclosed area(every 5 mm) are all 10 mm (5 mm per channel). Other sums of the lateralwidths of the channels are within the scope of the present disclosure.Example sums of the lateral widths may be in the range of 5 mm to 120mm, specifically reciting all 1 mm increments within the specified rangeand any ranges formed therein or thereby. The enclosed area may extendat least 5 mm, at least 10 mm, at least 15 mm, at least 20 mm, at least30 mm, at least 40 mm, at least 50 mm, at least 60 mm, or at least 70mm, for example, along the longitudinal axis 90′. The enclosed area maybe smaller for sanitary napkins since their absorbent cores aretypically smaller than diapers. Thus, the profile from FIG. 9 isconstant, or substantially constant, since the sum of the lateral widthsof the channels 26 and 26′ taken every 5 mm along the longitudinal axis80′ should have the same value. If only channel 26 were present in theenclosed area of FIG. 9, the profile would also be constant, orsubstantially constant, since the lateral width of the channel 26measured parallel to the lateral axis 90′ is constant, or substantiallyconstant, in this embodiment along the longitudinal length L′. Thesecond channel 26′ may be positioned on the opposite side of thelongitudinal axis 80′ as the first channel 26. The profile of the secondchannel 26′ may also be constant, or substantially constant, about alongitudinal length, such as L′ of FIG. 9, since the lateral width ofthe second channel 26′ is constant, or substantially constant, about thechannel's longitudinal length L′. In other embodiments, the lateralwidths of each channel 26 and 26′ may be constant, substantiallyconstant, or variable along a longitudinal length or a portion thereof.In other embodiments, one channel (e.g., channel 26) may have aconstant, or substantially constant, lateral width about itslongitudinal length, while the other channel (e.g., channel 26′) mayhave a varying lateral width about its longitudinal length. In theembodiment of FIG. 9, the channel 26 and the channel 26′ may have thesame longitudinal length along the longitudinal axis 80′. In otherembodiments, the first and second or more channels may each have adifferent longitudinal length along the longitudinal axis 80′.

The above is merely an example non-limiting configuration of how tomeasure the sum of the lateral widths over a particular longitudinallength along the longitudinal axis 80′. As discussed below, otherprofiles are also within the scope of the present disclosure based onthe configurations and/or orientations of the channels within themeasured longitudinal length and/or enclosed area.

Again referring to FIG. 9, a profile of the sum of the lateral widths ofthe channels 26 and 26′ over a portion of the longitudinal length on afirst side of the lateral axis 90′ may be different than a profile ofthe sum of the lateral widths of the channels 26 and 26′ over anotherportion of the longitudinal length on a second side of the lateral axis90′. In other embodiments, the profile of the sum of the lateral widthsof the channels 26 and 26′ over a portion of the longitudinal length onthe first side of the lateral axis 90′ may be the same, or substantiallythe same, as the profile of the sum of the lateral widths of thechannels 26 and 26′ over a portion of the longitudinal length on thesecond side of the lateral axis 90′

In an embodiment, referring to FIG. 1, the absorbent core 28 maycomprise at least three channels or four channels (e.g., 26, 26′, 27,27′). These channels may be free of, or substantially free of (e.g.,less than 10%, less than 5%, less than 3%, less than 2%, or less than1%), superabsorbent polymers and may be at least partially oriented inthe longitudinal direction and/or may be at least partially oriented inthe lateral direction. In various embodiments, the longitudinal lengthsof the channels 26 and 26′ about the longitudinal axis 80 may be thesame, substantially the same (e.g., within 2 mm or less of each other),or different and the longitudinal lengths of the channels 27 and 27′about the longitudinal axis 80 may be the same, substantially the same,or different. The longitudinal length of the channels 26 and 26′ may belarger than the longitudinal length of the channels 27 and 27′. Theaverage lateral width over the longitudinal lengths of the channels 27and 27′ may be the same, substantially the same, or may be different.Likewise, the average lateral width over the longitudinal lengths of thechannels 26 and 26′ may be the same, substantially the same, or may bedifferent. The average lateral width of any of the channels 26, 26′, 27,and 27′ may be the same, substantially the same, or different. Thisrationale may apply to any channel configurations disclosed herein.

In an embodiment, referring again to FIG. 1, at least two of the threechannels 26, 26′, 27, and 27′ may be at least partially oriented in thelongitudinal direction along of the longitudinal axis 80 of the article.Each of the channels 26, 26′, 27, and 27′ may have lateral widths takenparallel to the lateral axis 90. Referring to FIG. 11, a profile of thesum of the lateral widths of the channels over a longitudinal lengthalong the longitudinal axis 80 of at least 5 mm, at least 10 mm, atleast 15 mm, at least 20 mm, at least 25 mm, at least 30 mm, at least 35mm, at least 40 mm, at least 45 mm, at least 50 mm or greater takenalong the longitudinal axis 80 may have two maximum peaks “MP.” Themaximum peaks may be separated from each other by a gap “G” extending atleast 1 mm, at least 3 mm, at least 5 mm, at least 10 mm, at least 15mm, at least 20 mm or greater of the longitudinal length about thelongitudinal axis 80. An example of such a profile is illustrated inFIG. 11. The profile of FIG. 11 was taken between the longitudinallength represented by lines A and B every 5 mm in longitudinal length(represented by dots along the first side edge 3). Lines parallel to thelateral axis 90 and intersecting each dot should be drawn on theabsorbent article. The sum of the lateral width of the channels takenparallel to the lateral axis 90 should be measured on each line usingthe tape measure. Although the maximum peaks “MP” of FIG. 11 areillustrated separated by a 5 mm gap “G”, this gap could be less than 1mm or greater than 1 mm, for example, 1-15 mm or 1-9 mm.

Again referring to FIG. 11, the profile of the sum of the lateral widthsof the channels 26, 26′, 27, and/or 27′ over a longitudinal length of atleast 20 mm taken along the longitudinal axis 80 may be bimodal and mayhave a portion between the two modes where the sum of the lateral widthsof at least three of the channels 26, 26′, 27, and 27′ or all of thechannels is zero. This portion where the sum of the lateral widths of atleast three of the channels 26, 26′, 27, and 27′ or all of the channelsis zero is indicated by the gap G in FIG. 11.

In another embodiment, referring to FIG. 12, the absorbent core 28 maycomprise the first channel 26 and the second channel 26′ as describedabove and one or more pockets 29 that are free of, or substantially freeof, the superabsorbent polymers. As an example, the pocket 29 may have awidth dimension of 20 mm to 110 mm or less or greater, such as 90 mm(about the lateral axis 90′) and a length dimension of 30 mm to 00 mm orless or greater, such as 50 mm (about the longitudinal axis 80′). Theone or more pockets 29 may have a portion positioned on the longitudinalaxis 80′ and may be positioned in the front waist region 5, the rearwaist region 6, and/or the crotch region 7. In another embodiment, apocket may extend into two or more regions. Although FIGS. 9, 12 and14-20 only show an absorbent core 28, it will be understood that thefront waist region 5, the rear waist region 6, and the crotch region 7will generally correspond with such regions on the absorbent article asillustrated in FIG. 1. A portion of the one or more pockets 29 may notbe positioned on the longitudinal axis 80′. In an embodiment, the one ormore pockets 29 may have a portion positioned on the lateral axis 90′.The pocket 29 has lateral widths measured parallel to the lateral axis90′ and longitudinal lengths measured parallel to the longitudinal axis80′. A profile of the sum of the lateral widths of the first and secondchannels 26 and 26′ and the lateral widths of the pocket 29 over alongitudinal length of 50 mm taken along the longitudinal axis 80′ mayhave two separate, constant, or substantially constant portions, asillustrated in representative form in FIG. 13. FIG. 13 is the sum of thelateral widths of the superabsorbent polymer free, or substantiallysuperabsorbent polymer free, areas of the channels 26 and 26′ and thepocket 29 taken from line C to line D in FIG. 12. The longitudinallength along the longitudinal axis 80′ between lines C and D may be atleast 50 mm or less or more. As can be seen from FIG. 13, the profilehas two constant, or substantially constant portions, representing thesum of the lateral widths of the channels alone, and one portion largerthan the constant, or substantially constant portions, representing thesum of the lateral widths of the channels 26 and 26′ and the lateralwidths of the pocket 29. The sum of the lateral widths of the firstchannel 26, the second channel 26′, and the pocket 29 at a pointintermediate lines C and D may be in the range of about 20 mm to about100 mm, for example. The lateral widths should be measured every 5 mmalong the longitudinal axis 80′ as discussed above and between lines Cand D. The pocket 29 may be a bowel movement “BM” pocket configured toretain BM. In another embodiment, referring to FIG. 14, the pocket 29′may be positioned at least partially in the front waist region 5 and maybe a urine management or retention pocket. In still another embodiment,referring to FIG. 15, the pocket 29″ may be positioned at leastpartially in the crotch region 7 and may be a urine management orretention pocket and/or a BM pocket. The pocket 29″ may havelongitudinal side edges formed by the laterally inboard sides of thechannels 26 and 26′ or may have longitudinal side edges formedindependently of the laterally inboard side edges of the channels 26 and26′. The pockets 29, 29′, or 29″ may have lateral widths measuredparallel to the lateral axis 90′ every 5 mm along the longitudinal axis80′ in the range of 10 mm to 110 mm, 20 mm to 100 mm, or 30 mm to 95 mm,specifically reciting all 1 mm increments within the above-specifiedranges and any ranges formed therein or thereby.

In yet another embodiment, referring to FIG. 16, the absorbent core 28may comprise the first channel 26 and/or the second channel 26′ and athird channel 26″ (sometimes referred to in the claims as a secondchannel if one of the first and second channels 26 and 26′ are notrecited). The third channel 26″ may be free of, or substantially freeof, superabsorbent polymers and may be positioned in the rear waistregion 6, the crotch region 7, and/or the front waist region 5. Thethird channel 26″ may be positioned within 0-50 mm from the rear waistedge 12 or the rear side 282 or within 0-50 mm from the front waist edge10 or the front side 280. All 1 mm increments within the above-specifiedranges are specifically recited herein including any ranges formedtherein or thereby. A sum of the lateral widths of the first channel 26and the third channel 26″ or the first channel 26, the second channel26′, and the third channel 26″ at a point along the longitudinal axis(for example, point E of FIG. 16) that is 50 mm, or 30 mm, or 20 mm, or15 mm, or 10 mm, or 5 mm, or 1 mm, or less from the rear side 282 or therear waist edge 12 or the front side 280 or front waist edge 10 may begreater than zero. FIG. 17 illustrates an absorbent core 28 comprising afirst channel 26, a second channel 26′, a third channel 31, and a fourthchannel 31′. Any of these channels may be optional. The sum of thelateral widths of the third channel 31 and the fourth channel 31′ at apoint along the longitudinal axis 80′ (for example, point F of FIG. 17)that is 50 mm, or 30 mm, or 20 mm, or 15 mm, or 10 mm, or 5 mm, or 3 mm,or 1 mm, or less from the rear waist edge 12, the rear side 282, thefront waist edge 10, or the front side 280 may be greater than zero.

In an embodiment, referring to FIG. 18, the first channel 26 and thesecond channel 26′ may each have a first arcuate portion 33 in the frontwaist region 5 and a second arcuate portion 33′ in the rear waist region6. The arcuate portions 33 and 33′ may face the longitudinal axis 80′.The first channel 26 and the second channel 26′ may also have a thirdarcuate portion 33″ in the crotch region 7 or a non-arcuate portion in33″ the crotch region 7. The arcuate portions 33″ or the portions 33″may also face the longitudinal axis 80′. Tangent lines 35 of the arcuateportions 33 may intersect the longitudinal axis 80′ to create angle A1.The angle of intersection A1 between the tangent lines 35 and thelongitudinal axis 80′ may be in the range of 10 degrees to 80 degrees,20 degrees to 75 degrees, 30 degrees to 60 degrees, or 45 degrees.Tangent lines 35′ of the arcuate portions 33′ may intersect thelongitudinal axis 80′ to create angle A2. The angle of intersection A2between the tangent lines 35′ and the longitudinal axis 80′ may be inthe range of 10 degrees to 80 degrees, 20 degrees to 75 degrees, 30degrees to 60 degrees, or 45 degrees. Tangent lines 35″ of the arcuateportions 33″ may intersect the longitudinal axis 80′ to create angle A3.The angle of intersection A3 between the tangent lines 35″ and thelongitudinal axis 80′ may be in the range of 0.1 degrees to 35 degreesor 1 degree to 20 degrees. In an embodiment, tangent lines may extendfrom the non-arcuate portions 33″ in the crotch region 7. The tangentlines may not intersect the longitudinal axis 80′ and may instead extendin directions parallel to the longitudinal axis 80′. All 0.5 degreeincrements within the ranges specified in this paragraph are recitedherein including any ranges formed therein or thereby.

As can be seen in FIG. 18, the first tangent line 35 taken from thefirst arcuate portion 33 on a first side of the longitudinal axis 80′may have a positive slope (rise/run) and the first tangent line 35 takenfrom the first arcuate portion 33 on the second side of the longitudinalaxis 80′ may have a negative slope. The second tangent line 35′ takenfrom the second arcuate portion 33′ on a first side of the longitudinalaxis 80′ may have a negative slope and the second tangent line 35′ takenfrom the second arcuate portion 33′ on the second side of thelongitudinal axis 80′ may have a positive slope. The tangent lines 35″may also have a positive or a negative slope. The slopes of the varioustangent lines may be different if the configuration of the channels isdifferent.

Again referring to FIG. 18, angles A1, A2, and A3 on a first side of thelongitudinal axis 80′ may be different than, the same as, orsubstantially the same as angles A1, A2, and A3, respectively, on asecond side of the longitudinal axis 80′. In an embodiment, with respectto angles on one side of the longitudinal axis 80′, angle A1 may begreater than angles A2 and A3 and angle A2 may be greater than angle A3.In other embodiments, with respect to angles on one side of thelongitudinal axis 80′, angle A1 and angle A2 may be the same orsubstantially the same, while angle A3 may be less than angles A1 andA2. In still other embodiments, any of the angles on one side of thelongitudinal axis 80′ may be the same or different.

The tangent lines 35 are taken from portions of the arcuate portions 33in the front waist region 5. The tangent lines 35′ are taken fromportions of the arcuate portions 33′ in the rear waist region 6. Thetangent lines 35″ are taken from portions of the arcuate portions 33″ inthe crotch region 7.

The longitudinal axis 80 or 80′ can be drawn on an absorbent article orthe absorbent core, respectively, by connecting the midpoints of thefirst waist edge 10 or first side 280 and the second waist edge 12 orsecond side 282, respectively. The tangent lines can be drawn on theabsorbent article or the absorbent core using a straight edge. Multipletangent lines may be drawn on an arcuate portion in the front waistregion 5, the rear waist region 6, and/or the crotch region 7. Thetangent lines should be drawn long enough to intersect the longitudinalaxis 80 or 80′ unless they are positioned parallel to the longitudinalaxis 80 or 80′. A protractor, graduated in 1 degree increments, may thenbe used to measure the angles (A1, A2, and A3) between the tangent linesand the longitudinal axis 80 or 80′. If additional channels are presentin the absorbent core 28, additional tangent lines may be drawn on thosechannels in the same or a similar fashion.

In an embodiment, referring to FIG. 19, in additional to the first andsecond channels 26 and 26′ discussed above, an absorbent core maycomprise a channel or pocket 37 that is free of, or substantially freeof, superabsorbent polymers. A portion of the channel or pocket 37 maybe located on the longitudinal axis 80′. The channel or pocket 37 maycomprise an arcuate portion 39 facing the side 284 or the second sideedge 4 and another arcuate portion 39′ facing the side 282 or the firstside edge 3. An angle, A4, between a tangent line 41′ (or 41) of thearcuate portion 39′ (or 39) and the longitudinal axis 80′ may be in therange of about 0.1 degrees to 40 degrees, 0.1 degrees to 20 degrees, 0.1degrees to 15 degrees, 0.1 degrees to 10 degrees, or 0.1 degrees to fivedegrees, specifically reciting all 0.1 degree increments within theabove-specified ranges and any ranges formed therein or thereby. In anembodiment, the tangent line 41 (or 41′) may extend parallel to thelongitudinal axis 80′ and never intersect the longitudinal axis 80′. Thechannel or pocket 37 may be positioned at least partially within thefront waist region 5, the rear waist region 6, and/or the crotch region7.

In an embodiment, referring to FIG. 20, in addition to the first andsecond channels 26 and 26′, an absorbent core 28 may comprise a channelor a pocket 43 having a portion positioned on the longitudinal axis 80′.The channel or pocket 43 may have a longitudinal length in the range of10 mm to 150 mm and a lateral width of 10 mm to about 150 mm,specifically reciting all 1 mm increments within the specified rangesand all ranges formed therein or thereby. Other dimensions are alsowithin the scope of the present disclosure. The channel or the pocket 43may be located in the front waist region 5 or the rear waist region 6,or both. The channel or pocket 43 may have an arcuate portion 45 facingthe front side 280 or the front waist edge 10 if the channel or pocket43 is located in the front waist region 5 and an arcuate portion 45facing the rear side 282 or the rear waist region 12 if the channel orpocket 43 is located in the rear waist region 6. The channel or pocket43 may extend into the crotch region 7 in some instances. A tangent line47 of the arcuate portion 45 may create an angle with the longitudinalaxis 80′ in the range of 70 degrees to 110 degrees, 80 degrees to 100degrees, 85 degrees to 85 degrees, about 90 degrees, or 90 degrees,specifically reciting all 0.5 degree increments within the specifiedranges and any ranges formed therein or thereby.

In an embodiment, referring to FIG. 21, in addition to the first andsecond channels 26 and 26′, an absorbent core 28 may comprise a pocket53 in the crotch region 7 and/or the rear waist region 6 and one or morechannels 55 in the rear waist region 6 and/or the crotch region 7. Inanother embodiment, the pocket 53 may be in the crotch region 7 and/orthe front waist region 5 and the one or more channels 55 may be in thecrotch region 7 and/or the front waist region 5. The pocket 53 and theone or more channels 55 may be BM pockets or channels and/or urinemanagement pockets and/or channels. The channels 55 may extend generallyin the lateral direction about the lateral axis 90′. The variousparameters discussed herein may apply to FIG. 21, if suitable. Forinstance, at least one, or all of, the channels 55 may have a tangentline 59 extending from an arcuate portion 57 thereof. The angle formedbetween the tangent line 59 and the longitudinal axis 80′ may be 80degrees to 100 degrees, about 90 degrees, or 90 degrees, for example.

Barrier Leg Cuffs

The absorbent article may comprise a pair of barrier leg cuffs 34. Eachbarrier leg cuff may be formed by a piece of material which is bonded tothe article so it can extend upwards from the inner surface of thearticle and provide improved containment of liquids and other bodyexudates approximately at the junction of the torso and legs of thewearer. The barrier leg cuffs are delimited by a proximal edge 64 joineddirectly or indirectly to the topsheet 24 and/or the backsheet 25 and afree terminal edge 66, which is intended to contact and form a seal withthe wearer's skin. The barrier leg cuffs extend at least partiallybetween the front waist edge 10 and the rear waist edge 12 of theabsorbent article on opposite sides of the longitudinal axis 80 and areat least present at the level of the crotch point (C) or crotch region.The barrier leg cuffs may be joined at the proximal edge 64 with thechassis of the article by a bond 65 which may be made by gluing, fusionbonding, or combination of other suitable bonding processes. The bond 65at the proximal edge 64 may be continuous or intermittent. The bond 65closest to the raised section of the leg cuffs delimits the proximaledge 64 of the standing up section of the leg cuffs.

The barrier leg cuffs may be integral with the topsheet 24 or thebacksheet 25 or may be a separate material joined to the article'schassis. The material of the barrier leg cuffs may extend through thewhole length of the diapers but may be “tack bonded” to the topsheet 24towards the front waist edge 10 and rear waist edge 12 of the article sothat in these sections the barrier leg cuff material remains flush withthe topsheet 24.

Each barrier leg cuff 34 may comprise one, two or more elastic strings35 close to this free terminal edge 66 to provide a better seal.

In addition to the barrier leg cuffs 34, the article may comprisegasketing cuffs 32, which are joined to the chassis of the absorbentarticle, in particular to the topsheet 24 and/or the backsheet 25 andare placed externally relative to the barrier leg cuffs. The gasketingcuffs 32 may provide a better seal around the thighs of the wearer. Eachgasketing leg cuff may comprise one or more elastic strings or elasticelements in the chassis of the absorbent article between the topsheet 24and backsheet 25 in the area of the leg openings.

U.S. Pat. No. 3,860,003 describes a disposable diaper which provides acontractible leg opening having a side flap and one or more elasticmembers to provide an elasticized leg cuff (a gasketing cuff). U.S. Pat.No. 4,808,178 and U.S. Pat. No. 4,909,803 issued to Aziz et al.describes disposable diapers having “stand-up” elasticized flaps(barrier leg cuffs) which improve the containment of the leg regions.U.S. Pat. No. 4,695,278 and U.S. Pat. No. 4,795,454 issued to Lawson andto Dragoo respectively, describe disposable diapers having dual cuffs,including gasketing cuffs and barrier leg cuffs. All or a portion of thebarrier leg and/or gasketing cuffs may be treated with a lotion.

Acquisition-Distribution System

The absorbent articles of the present disclosure may comprise anacquisition-distribution layer or system 50 (herein “ADS”). One functionof the ADS is to quickly acquire the fluid and distribute it to theabsorbent core in an efficient manner. The ADS may comprise one, two ormore layers, which may form a unitary layer or may remain as discretelayers which may be attached to each other. In an embodiment, the ADSmay comprise two layers: a distribution layer 54 and an acquisitionlayer 52 disposed between the absorbent core and the topsheet, but thepresent disclosure is not limited to this embodiment.

The ADS may comprise SAP as this may slow the acquisition anddistribution of the fluid. Suitable ADS are described in WO 2000/59430(Daley), WO 95/10996 (Richards), U.S. Pat. No. 5,700,254 (McDowall), andWO 02/067809 (Graef), for example.

Distribution Layer

The distribution layer of the ADS may comprise at least 50% by weight ofcross-linked cellulose fibers. The cross-linked cellulosic fibers may becrimped, twisted, or curled, or a combination thereof including crimped,twisted, and curled. This type of material is disclosed in U.S. Pat.Publ. No. 2008/0312622 A1 (Hundorf). The cross-linked cellulosic fibersprovide higher resilience and therefore higher resistance to the firstabsorbent layer against the compression in the product packaging or inuse conditions, e.g., under baby weight. This provides the core with ahigher void volume, permeability, and liquid absorption, and hencereduced leakage and improved dryness.

Example chemically cross-linked cellulosic fibers suitable for adistribution layer are disclosed in U.S. Pat. No. 5,549,791, U.S. Pat.No. 5,137,537, WO 9534329, or U.S. Pat. Publ. No. 2007/118087. Examplecross-linking agents include polycarboxylic acids such as citric acidand/or polyacrylic acids such as acrylic acid and maleic acidcopolymers.

The distribution layer comprising cross-linked cellulose fibers of thepresent disclosure may comprise other fibers, but this layer mayadvantageously comprise at least 50%, or 60%, or 70%, or 80%, or 90%, oreven up to 100%, by weight of the layer, of cross-linked cellulosefibers (including the cross-linking agents). Examples of such mixedlayer of cross-linked cellulose fibers may comprise about 70% by weightof chemically cross-linked cellulose fibers, about 10% by weightpolyester (PET) fibers, and about 20% by weight untreated pulp fibers.In another example, the layer of cross-linked cellulose fibers maycomprise about 70% by weight chemically cross-linked cellulose fibers,about 20% by weight lyocell fibers, and about 10% by weight PET fibers.In another example, the layer may comprise about 68% by weightchemically cross-linked cellulose fibers, about 16% by weight untreatedpulp fibers, and about 16% by weight PET fibers. In another example, thelayer of cross-linked cellulose fibers may comprise from about 90-100%by weight chemically cross-linked cellulose fibers.

The distribution layer 54 may be a material having a water retentionvalue of from 25 to 60 or from 30 to 45, measured as indicated in theprocedure disclosed in U.S. Pat. No. 5,137,537.

The distribution layer may typically have an average basis weight offrom 30 to 400 g/m² or from 100 to 300 g/m², specifically reciting all1.0 g/m² increments within the above-specified ranges and any rangesformed therein or thereby. The density of the distribution layer mayvary depending on the compression of the article, but may be between0.03 to 0.15 g/cm³ or 0.08 to 0.10 g/cm³, specifically reciting all 1.0g/cm³ increments within the above-specified ranges and any ranges formedtherein or thereby, measured at 0.30 psi (2.07 kPa).

Acquisition Layer

The ADS may comprise an acquisition layer 52. The acquisition layer maybe disposed between the distribution layer 54 and the topsheet 24. Theacquisition layer 52 may be or may comprise a non-woven material, suchas an SMS or SMMS material, comprising a spunbonded, a melt-blown and afurther spunbonded layer or alternatively a carded chemical-bondednonwoven. The nonwoven material may be latex bonded. Example upperacquisition layers 52 are disclosed in U.S. Pat. No. 7,786,341. Carded,resin-bonded nonwovens may be used, in particular where the fibers usedare solid round or round hollow PET staple fibers (50/50 or 40/60 mix of6 denier and 9 denier fibers). An example binder is a butadiene/styrenelatex. Nonwovens have the advantage that they can be manufacturedoutside the converting line and stored and used as a roll of material.

The acquisition layer 52 may be stabilized by a latex binder, forexample a styrene-butadiene latex binder (SB latex).

A further acquisition layer may be used in addition to a firstacquisition layer described above. For example, a tissue layer may beplaced between the first acquisition layer and the distribution layer.The tissue may have enhanced capillarity distribution propertiescompared to the acquisition layer described above. The tissue and thefirst acquisition layer may be of the same size or may be of a differentsize. For example, the tissue layer may extend further in the rear ofthe absorbent article than the first acquisition layer. An example ofhydrophilic tissue is a 13-15 gsm high wet strength made of cellulosefibers from supplier Havix.

Fastening System

The absorbent article may include a fastening system. The fasteningsystem may be used to provide lateral tensions about the circumferenceof the absorbent article to hold the absorbent article on the wearer asis typical for taped diapers. This fastening system may not be necessaryfor training pant articles since the waist region of these articles isalready bonded. The fastening system may comprise a fastener such astape tabs, hook and loop fastening components, interlocking fastenerssuch as tabs & slots, buckles, buttons, snaps, and/or hermaphroditicfastening components, although any other suitable fastening mechanismsare also within the scope of the present disclosure. A landing zone 44is normally provided on the garment-facing surface of the front waistregion 5 for the fastener to be releasably attached thereto. Someexample surface fastening systems are disclosed in U.S. Pat. No.3,848,594, U.S. Pat. No. 4,662,875, U.S. Pat. No. 4,846,815, U.S. Pat.No. 4,894,060, U.S. Pat. No. 4,946,527, U.S. Pat. No. 5,151,092, andU.S. Pat. No. 5,221,274. An example interlocking fastening system isdisclosed in U.S. Pat. No. 6,432,098. The fastening system may alsoprovide a mechanism for holding the article in a disposal configurationas disclosed in U.S. Pat. No. 4,963,140 issued to Robertson et al.

The fastening system may also include primary and secondary fasteningsystems, as disclosed in U.S. Pat. No. 4,699,622 to reduce shifting ofoverlapped portions or to improve fit as disclosed in U.S. Pat. No.5,242,436, U.S. Pat. No. 5,499,978, U.S. Pat. No. 5,507,736, and U.S.Pat. No. 5,591,152.

Front and Rear Ears

In an embodiment, the absorbent article may comprise front ears 46 andrear ears 40. The ears may be an integral part of the chassis, such asformed from the topsheet 24 and/or backsheet 26 as side panel.Alternatively, as represented on FIG. 1, the ears may be separateelements attached by gluing, heat embossing, and/or pressure bonding.The rear ears 40 may be stretchable to facilitate the attachment of thetabs 42 to the landing zone 44 and maintain the taped diapers in placearound the wearer's waist. The rear ears 40 may also be elastic orextensible to provide a more comfortable and contouring fit by initiallyconformably fitting the absorbent article to the wearer and sustainingthis fit throughout the time of wear well past when absorbent articlehas been loaded with exudates since the elasticized ears allow the sidesof the absorbent article to expand and contract.

Elastic Waist Feature

The absorbent article may also comprise at least one elastic waistfeature (not represented) that helps to provide improved fit andcontainment. The elastic waist feature is generally intended toelastically expand and contract to dynamically fit the wearer's waist.The elastic waist feature may extend at least longitudinally outwardlyfrom at least one waist edge of the absorbent core 28 and generallyforms at least a portion of the end edge of the absorbent article.Disposable diapers may be constructed so as to have two elastic waistfeatures, one positioned in the front waist region and one positioned inthe rear waist region. The elastic waist feature may be constructed in anumber of different configurations including those described in U.S.Pat. No. 4,515,595, U.S. Pat. No. 4,710,189, U.S. Pat. No. 5,151,092,and U.S. Pat. No. 5,221,274.

Relations Between the Layers

Typically, adjacent layers and components may be joined together usingconventional bonding methods, such as adhesive coating via slot coatingor spraying on the whole or part of the surface of the layer,thermo-bonding, pressure bonding, or combinations thereof. This bondingis not represented in the Figures (except for the bonding between theraised element of the leg cuffs 65 with the topsheet 24) for clarity andreadability, but bonding between the layers of the article should beconsidered to be present unless specifically excluded. Adhesives may beused to improve the adhesion of the different layers between thebacksheet 25 and the core wrap. The glue may be any suitable hotmeltglue known in the art.

If an acquisition layer 52 is present, it may be desired that thisacquisition layer is larger than or least as large as the distributionlayer 54 in the longitudinal and/or transversal dimension. Thus, thedistribution layer 52 may be deposited on the acquisition layer. Thissimplifies handling, in particular if the acquisition layer is anonwoven which may be unrolled from a roll of stock material. Thedistribution layer may also be deposited directly on the absorbentcore's upper side of the core wrap or another layer of the article.Also, having an acquisition layer 52 that is larger than thedistribution layer allows for direct gluing of the acquisition layer tothe storage core (at the larger areas). This may provide increased patchintegrity and better liquid communication.

The absorbent core and in particular its absorbent material depositionarea 8 may be at least as large and long and at least partially largerand/or longer than the acquisition-distribution system (ADS). This isbecause the absorbent material in the core may more effectively retainfluid and provide dryness benefits across a larger area than the ADS.The absorbent article may have a rectangular SAP layer and anon-rectangular (shaped) ADS. The absorbent article may also have arectangular (non-shaped) ADS and a rectangular layer of SAP.

Sanitary Napkin Features

In an embodiment, referring to FIG. 22, the absorbent article may be asanitary napkin 3010. The sanitary napkin 3010 may comprise a liquidpermeable topsheet 3014, a liquid impermeable, or substantially liquidimpermeable, backsheet 3016, and an absorbent core 3018. The absorbentcore 3018 may have any or all of the features described herein withrespect to the absorbent cores 28 and, in some embodiments, may have asecondary topsheet instead of the acquisition-distribution systemdisclosed above. The sanitary napkin 3010 may also comprise wings 3020extending outwardly with respect to a longitudinal axis 3080 of thesanitary napkin 3010. The sanitary napkin 3010 may also comprise alateral axis 3090. The wings 3020 may be joined to the topsheet 3014,the backsheet 3016, and/or the absorbent core 3018. The sanitary napkin3010 may also comprise a front edge 3022, a rear edge 3024longitudinally opposing the front edge 3022, a first side edge 3026, anda second side edge 3028 longitudinally opposing the first side edge3026. The longitudinal axis 3080 may extend from a midpoint of the frontedge 3022 to a midpoint of the rear edge 3024. The lateral axis 3090 mayextend from a midpoint of the first side edge 3028 to a midpoint of thesecond side edge 3028. The sanitary napkin 3010 may also be providedwith additional features commonly found in sanitary napkins as is knownin the art.

Method of Making the Article

The absorbent articles and sanitary napkins of the present disclosuremay be made by any suitable methods known in the art. In particular, thearticles may be hand-made or industrially produced at high speed.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany embodiment disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such embodiment. Further, to the extent that any meaningor definition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present disclosure have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications may be made withoutdeparting from the spirit and scope of the present disclosure. It istherefore intended to cover in the appended claims all such changes andmodifications that are within the scope of this disclosure.

What is claimed is:
 1. An absorbent article comprising: a front waistedge; a rear waist edge longitudinally opposing the front waist edge; afirst side edge; a second side edge laterally opposing the first sideedge; a longitudinal axis extending from a midpoint of the front waistedge to a midpoint of the rear waist edge; a lateral axis extending froma midpoint of the first side edge to a midpoint of the second side edge;a liquid permeable topsheet; a liquid impermeable backsheet; a pair ofbarrier leg cuffs extending at least partially between the front waistedge and the rear waist edge on opposite sides of the longitudinal axis,wherein each barrier leg cuff comprises: a proximal edge joined to thetopsheet or the backsheet; and a free terminal edge; and an absorbentcore disposed at least partially intermediate the topsheet and thebacksheet and comprising a core wrap enclosing an absorbent material,wherein the core wrap comprises a first nonwoven and a second nonwoven,wherein the first nonwoven forms a C-wrap at least partially around thesecond nonwoven, wherein the absorbent material comprises at least 80%of superabsorbent polymers by weight of the absorbent material, whereinthe absorbent core comprises a channel substantially free of thesuperabsorbent polymers, at least partially oriented in the longitudinaldirection of the article, and comprising an arcuate portion, wherein thefirst nonwoven is in contact with the second nonwoven in at least aportion of the channel, wherein the channel has lateral widths takenparallel to the lateral axis, and wherein a profile of the lateralwidths of the channel over a longitudinal length of at least 50 mm ofthe channel taken along the longitudinal axis is substantially constant.2. The absorbent article of claim 1, wherein the substantially constantlateral width is in the range of about 5 mm to about 10 mm.
 3. Theabsorbent article of claim 1, wherein the absorbent core comprises asecond channel substantially free of the superabsorbent polymers and atleast partially oriented in the longitudinal direction of the article,wherein the second channel has lateral widths taken parallel to thelateral axis, and wherein the second channel is positioned on anopposite side of the longitudinal axis as the channel.
 4. The absorbentarticle of claim 3, wherein a profile of the lateral widths of thesecond channel over the longitudinal length is substantially constant.5. The absorbent article of claim 3, wherein the lateral widths of thesecond channel vary over the longitudinal length.
 6. The absorbentarticle of claim 3, wherein the channel and the second channel have thesame longitudinal length within the absorbent article.
 7. The absorbentarticle of claim 3, wherein the lateral widths of the channel and thesecond channel are substantially the same at a point along the channeland the second channel.
 8. The absorbent article of claim 1, wherein theabsorbent core comprises at least three channels substantially free ofthe superabsorbent polymers and at least partially oriented in thelongitudinal direction, wherein the longitudinal length of two of thechannels is substantially the same, and wherein the longitudinal lengthof the other channel is different.
 9. The absorbent article of claim 8,wherein the average lateral width over the longitudinal length of thethird channel is different than the average lateral width over thelongitudinal length of the channel or the second channel.
 10. Anabsorbent article comprising: a front waist edge; a rear waist edgelongitudinally opposing the front waist edge; a first side edge; asecond side edge laterally opposing the first side edge; a longitudinalaxis extending from a midpoint of the front waist edge to a midpoint ofthe rear waist edge; a lateral axis extending from a midpoint of thefirst side edge to a midpoint of the second side edge; a liquidpermeable topsheet; a liquid impermeable backsheet; a pair of barrierleg cuffs extending at least partially between the front waist edge andthe rear waist edge on opposite sides of the longitudinal axis, whereineach barrier leg cuff comprises: a proximal edge joined to the topsheetor the backsheet; and a free terminal edge; and an absorbent coredisposed at least partially intermediate the topsheet and the backsheetand comprising a core wrap enclosing an absorbent material, wherein thecore wrap comprises a first material and a second material, wherein thefirst material forms a C-wrap at least partially around the secondmaterial, wherein the absorbent material comprises at least 80% ofsuperabsorbent polymers by weight of the absorbent material, wherein theabsorbent core comprises three channels substantially free of thesuperabsorbent polymers, wherein at least two of the three channels areat least partially oriented in the longitudinal direction of thearticle, wherein the channels each have lateral widths taken parallel tothe lateral axis, wherein a profile of the sum of the lateral widths ofthe channels over a longitudinal length of at least 20 mm taken alongthe longitudinal axis has two maximum peaks, and wherein the maximumpeaks are separated from each other by at least 3 mm of the longitudinallength.
 11. The absorbent article of claim 10, wherein a profile of thesum of the lateral widths of the channels over the longitudinal lengthon a first side of the lateral axis is different than a profile of thesum of the lateral widths of the channels over the longitudinal lengthon a second side of the lateral axis.
 12. The absorbent article of claim10, comprising an acquisition-distribution system comprising one or morelayers, and wherein the acquisition-distribution system is at leastpartially positioned intermediate the absorbent core and the topsheet.13. The absorbent article of claim 12, wherein theacquisition-distribution system comprises two layers, and wherein onelayer comprises at least 50% by weight of cross-linked cellulose fibers.14. The absorbent article of claim 10, wherein the absorbent corecomprises: a first absorbent layer comprising the first material and afirst layer of the superabsorbent polymers; a second absorbent layercomprising the second material and a second layer of the superabsorbentpolymers; and a fibrous thermoplastic adhesive material at leastpartially bonding the layers of the superabsorbent polymers to theirrespective materials.
 15. The absorbent core of claim 10, wherein theabsorbent material comprises at least 95% by weight of thesuperabsorbent polymers by total weight of the absorbent material. 16.The absorbent article of claim 10, wherein the absorbent material of theabsorbent core comprises less than 5% weight percent of natural orsynthetic fibers.
 17. The absorbent article of claim 10, wherein thefirst material and the second material are bonded to each other througha portion of one of the channels.
 18. An absorbent article comprising: afront waist edge; a rear waist edge longitudinally opposing the frontwaist edge; a first side edge; a second side edge laterally opposing thefirst side edge; a longitudinal axis extending from a midpoint of thefront waist edge to a midpoint of the rear waist edge; a lateral axisextending from a midpoint of the first side edge to a midpoint of thesecond side edge; a liquid permeable topsheet; a liquid impermeablebacksheet; a pair of barrier leg cuffs extending at least partiallybetween the front waist edge and the rear waist edge on opposite sidesof the longitudinal axis, wherein each barrier leg cuff comprises: aproximal edge joined to the topsheet or the backsheet; and a freeterminal edge; and an absorbent core disposed at least partiallyintermediate the topsheet and the backsheet and comprising a core wrapenclosing an absorbent material, wherein the core wrap comprises a firstnonwoven and a second nonwoven, wherein the first nonwoven forms aC-wrap at least partially around the second nonwoven, wherein theabsorbent material comprises at least 90% of superabsorbent polymers byweight of the absorbent material, wherein the absorbent core comprisesthree channels substantially free of the superabsorbent polymers,wherein at least two of the three channels are at least partiallyoriented in the longitudinal direction of the article, wherein thechannels each have lateral widths taken parallel to the lateral axis,wherein a profile of the sum of the lateral widths of the channels overa longitudinal length of at least 20 mm taken along the longitudinalaxis is bimodal and has a portion between the two modes where the sum ofthe lateral widths of the three channels is zero.
 19. The absorbentarticle of claim 18, wherein the first nonwoven and the second nonwovenare bonded to each other through a portion of one of the channels. 20.The absorbent article of claim 18, wherein the absorbent core comprises:a first absorbent layer comprising the first nonwoven and a first layerof the superabsorbent polymers; a second absorbent layer comprising thesecond nonwoven and a second layer of the superabsorbent polymers; and afibrous thermoplastic adhesive material at least partially bonding thelayers of the superabsorbent polymers to their respective nonwovens. 21.A sanitary napkin comprising: a front edge; a rear edge longitudinallyopposing the front edge; a first side edge; a second side edge laterallyopposing the first side edge; a longitudinal axis extending from amidpoint of the front edge to a midpoint of the rear edge; a lateralaxis extending from a midpoint of the first side edge to a midpoint ofthe second side edge; a liquid permeable topsheet; a liquid impermeablebacksheet; and an absorbent core disposed at least partiallyintermediate the topsheet and the backsheet and comprising a core wrapenclosing an absorbent material, wherein the core wrap comprises a firstmaterial and a second material, wherein the first material forms aC-wrap at least partially around the second material, wherein theabsorbent material comprises at least 80% of superabsorbent polymers byweight of the absorbent material, wherein the absorbent core comprises achannel substantially free of the superabsorbent polymers, at leastpartially oriented in the longitudinal direction of the sanitary napkin,and comprising an arcuate portion, wherein the first material and thesecond material are bonded to each other through a portion of thechannel, wherein the channel has lateral widths taken parallel to thelateral axis, and wherein a profile of the lateral widths of the channelover a longitudinal length of at least 15 mm of the channel taken alongthe longitudinal axis is substantially constant.
 22. The absorbentarticle of claim 21, wherein the absorbent core comprises: a firstabsorbent layer comprising the first material and a first layer of thesuperabsorbent polymers; and a second absorbent layer comprising thesecond material and a second layer of the superabsorbent polymers. 23.The absorbent core of claim 21, wherein the absorbent material comprisesat least 95% by weight of the superabsorbent polymers by total weight ofthe absorbent material.
 24. The absorbent article of claim 21, whereinthe absorbent material of the absorbent core comprises less than 5%weight percent of natural or synthetic fibers.
 25. A sanitary napkincomprising: a front edge; a rear edge longitudinally opposing the frontedge; a first side edge; a second side edge laterally opposing the firstside edge; a longitudinal axis extending from a midpoint of the frontedge to a midpoint of the rear edge; a lateral axis extending from amidpoint of the first side edge to a midpoint of the second side edge; aliquid permeable topsheet; a liquid impermeable backsheet; and anabsorbent core disposed at least partially intermediate the topsheet andthe backsheet and comprising a core wrap enclosing an absorbentmaterial, wherein the core wrap comprises a first material and a secondmaterial, wherein the first material forms a C-wrap at least partiallyaround the second material, wherein the absorbent material comprises atleast 80% of superabsorbent polymers by weight of the absorbentmaterial, wherein the absorbent core further comprises: a firstabsorbent layer comprising the first material and a first layer of thesuperabsorbent polymers; a second absorbent layer comprising the secondmaterial and a second layer of the superabsorbent polymers; and achannel substantially free of the superabsorbent polymers, at leastpartially oriented in the longitudinal direction of the sanitary napkin,and comprising an arcuate portion, wherein the channel has lateralwidths taken parallel to the lateral axis, and wherein a profile of thelateral widths of the channel over a longitudinal length of at least 15mm of the channel taken along the longitudinal axis is substantiallyconstant.
 26. The absorbent article of claim 25, wherein the firstmaterial and the second material are bonded to each other through aportion of the channel.
 27. The absorbent core of claim 25, wherein theabsorbent material comprises at least 95% by weight of thesuperabsorbent polymers by total weight of the absorbent material. 28.The absorbent article of claim 25, wherein the absorbent material of theabsorbent core comprises less than 5% weight percent of natural orsynthetic fibers.